Weichai WP7 - Service Manual

Operation & Maintenance Manual and User Service Guide
WP7 Euro Ⅵ Vehicle Diesel Engine

Operation & Maintenance Manual and User
Service Guide
610800820289
Foreword
WP7 Euro Ⅵ vehicle diesel engines are developed based on a new design
concept and meet the Euro Ⅵ emission standard. WP7 diesel engines feature
compact structure, reliable operation, high economy indexes and power performance,
quick startup, easy operation and convenient maintenance and are the ideal power for
the middle/heavy-duty trucks and middle/large buses.
This manual, as reference, describes methods of operation and maintenance,
inspection essentials and service guide for WP7 diesel engines.
To make best use of WP7 diesel engines, users are expected to carefully read and
learn the diesel engine structure, maintenance and operation methods. The diesel
engine service life can be significantly prolonged if the users can follow this manual
during maintenance.
With the increasing numbers and improving of the variants of WP7 vehicle diesel
engines, users are expected to timely pay attention to the technical information
released by Weichai. Any revision will not be notified in advance. For more
information about new products, please visit http://en.weichai.com.
March. 2014
Special instructions
1) It is very dangerous to increase the power by modifying the ECU data. Any
change of ECU data without permit will lead to invalid “Three guarantees”
and so on, and all losses and the legal responsibilities arising therefore would
be borne by the users.
2) Common-rail fuel pump, turbocharger, urea solution injection system and
other components, as the precision parts, should not be impacted or dismantled
without permission; otherwise the "Three guarantees" will be invalid.
3) Please use Weichai designated fuel strainer and fine filter; otherwise any
damage to the common-rail system will not be covered by the “Three
guarantees”.
4) For Euro Ⅵ Diesel Engine, in order to make sure the normal operation of
the SCR processor, please add urea solution produced by formal manufactures
timely. It is forbidden to use urea solution mixed privately or other solutions,
otherwise, all losses and the legal responsibilities arising therefrom would be
borne by the users.
5) Please go to the formal fuel station to refill the stipulated fuel, otherwise any
damage to the fuel system due to fuel quality will not be covered by the “Three
guarantees”.
6) For Euro Ⅵ diesel engine, special Euro Ⅵ diesel fuel should be used,
otherwise any problems arising therefrom, such as the emissions exceeded the
limits of standard, should be borne by the users.
7) Any service such as repair or maintenance should be done at the designated
service station and spare parts specified by Weichai Power should be used;
otherwise, any damage to the diesel engines should be borne by the users.
8) The product norm follows Q/WCG 100.
Notice
1. Before the first use, the engine should go through a 50h trial run. For more
information, refer to the running-in requirements.
2. After the cold start, the engine should slowly increase the speed. Don’t let the
engine run at idle speed for a long time or suddenly speed up. After running with
heavy load, do not immediately stop. It is necessary to idle for 5-10 min at low
speed.
3. It is prohibited to work without air filters which could prevent air from entering
the cylinder without being filtrated. The air filter should be regularly maintained
or replaced, otherwise power reduction, parts wearing and other problems would
happen.
4. Please select specified grades of fuel and oil and use the special and clean
containers. The fuel and oil should be filtrated with the strainer before being
added.
5. If the diesel engine fails to start within 15s, repeat after at least 2 min.
6. It is prohibited to fill the diesel engine with water rather than antifreeze, which
could greatly reduce the engine life and leads to damage of the after-treatment
system and other parts.
7. Before the start, please ensure the antifreeze, urea solution and oil are at the
proper levels.
8. The strainer of urea solution tank must be cleaned regularly, otherwise the OBD
system will giving alarm.
9. When the vehicle is parked for a long time and the ambient temperature is lower
than the freezing point of antifreeze, it is necessary to drain the water out
through the discharge valve of the air compressor.
10. It is not allowed to reuse the cylinder head gasket and all kinds of asbestos or
metal coated sheet gaskets.
11. Feedback of engine quality information
Our company performs the quality-trace filing for WP7 diesel engines, therefore
users are expected to fill the card and send it back to our company for further
service based on the card.
CONTENTS
WP7 Euro Ⅵ diesel engine outside view ........................................................................... 6

The meaning of diesel engine model .................................................................................... 7
Diesel Base Parameter .......................................................................................................... 7
Tools and equipments:.......................................................................................................... 8
I. Operation & Maintenance Manual for WP7 Euro Ⅵ Vehicle Diesel Engines .. 1
1 Fuel, lubricating oil, antifreeze and auxiliary material for the diesel engines
.......................................................................................................... 1
1.1 Fuel ............................................................................................................................ 1
1.2 Lubricating oil ........................................................................................................... 1
1.3 Antifreeze .................................................................................................................. 2
1.4 Urea Solution .................................................................................................................. 2
1.5 Features of Weichai Power special oil ....................................................................... 3
1.6 Difference between the Weichai Power special oil and common oils ....................... 4
1.7 Some Common Products of Weichai Power Special Oils .............................................. 5
1.8 Corresponding table between the Weichai Power special oil and engine models ..... 5
1.9 How to select proper viscosity ................................................................................... 6
1.10 Auxiliary materials .................................................................................................... 6
2 Regular inspection and maintenance of diesel engine ............................... 7
3 Common failures and Troubleshooting ................................................. 12
II. User Service Guide (warranty card).............................................................. 21
Weichai Power Product Warranty Card (Kept by user) ....................................... 21
Service Registration Form (filled by the service staff) .................................. 22
Warranty Explanations ............................................................................. 23
“Three guarantees” period for diesel engine of Weichai Power ..................... 26
Weichai international marketing service network ......................................... 27
The European Union representative office ......................................................................... 29
Diesel engine mandatory maintenance card ................................................. 30
Customer Satisfaction Questionnaire .......................................................... 33
WP7 Euro Ⅵ diesel engine outside view

The meaning of diesel engine model
WP 7 . 270 E6 1
transmutation type
emission level
E6 stands for Euro Ⅵ emission
rated power (horsepower)
space, no meaning
displacement
Weichai Power company
Diesel Base Parameter
the Parameter of WP7 Euro Ⅵ diesel engine

Model Unit WP7.270E61
Type 6 cylinder Inline
Intake TDI
Bore × Journey mm ×mm 108×136
displace L 7.47
Rated power/ speed kW/r/min 199/2100
BSFC @rated speed g/kW∙h 205
Max torque/speed n∙m/r/min 1050/1200~1700
Max speed r/min 2500±50
Idle speed r/min 700±50
Fire order 1-5-3-6-2-4
Noise dB(A) ≤118
weight kg 700±20
Life of B10 km 800,000
Period of oil change km 20,000
Tools and equipments:
torque wrench sleeve wrench adjusted wrench

depth gauge micrometer piston ring plier dial indicator
screwdriver copper hammer orientation sleeve
pressure oil spot filler gauge diameter gauge micrometer
Operation & Maintenance Manual for WP7 Euro Ⅵ
Vehicle Diesel Engine
I. Operation & Maintenance Manual for WP7 Euro Ⅵ

Vehicle Diesel Engines
1 Fuel, lubricating oil, antifreeze and auxiliary material for the
diesel engines
1.1 Fuel
Summer: use the #0 diesel fuel.
Winter: use the #-10 diesel fuel under general conditions, use the #-20 diesel fuel
when the atmospheric temperature is below -15℃，and #-35 diesel fuel when below
-30℃.
The fuel to be filled should meet the standard in appendix C.6 of national standard
GB 17691-2005.
1.2 Lubricating oil
1.2.1 For WP7 Euro Ⅵ series diesel engines, use oil with higher grade than CI-4
or CJ-4.
1.2.2. It is allowed to use the oil of higher grade instead of oil of lower grade.
1.2.3 If the ambient temperature is -15℃ or higher, use the 15W/40 oil; if the
ambient temperature is -15℃ or lower, use the 5W/20 oil.
(Weichai Power special oil should be used, see sections from 1.5 to1.8)
Before the startup of diesel engine, check the oil level in the oil sump.
1. Do not check the oil level during operation.

2. It is not allowed to mix the oils of different grades.
1
Table 1-1 Selection of oil grade

Ambient
tempera
Multi-
ture grade oil
Due to the flat viscosity curve, the multi-grade oil has excellent lubricating
characteristics at lower and higher temperatures.
1.3 Antifreeze
1.3.1 The cooling system should be filled with long-lasting antifreeze fro rust-
proofing and antifreezing.
1.3.2 For the long-lasting antifreeze formulation, please refer to the instruction of
antifreeze. Some domestic long-lasting antifreezes are shown in Table 1-2.
Table 1-2 Domestic long-lasting antifreeze.
Item Grade JFL-318 JFL-336 JFL-345
Glycol content % 33 50 56
Specific gravity
1.05 1.074 1.082
(15.6℃)
Boiling point ℃ 104.5±1 108.5±1 110.0±1
Freezing point ℃ -18±1 -36±1 -45±1
Applicable lowest
-10 -26 -35
temperature ℃
1.4 Urea Solution
Product Properties for urea solution as per the revised ISO22241 standard. See Table
1-3 for details.
Table 1-3 Requirements on Urea solution (Refer to ISO22241)
2
Items Unit Min limit Max limit

Urea content % by weight 31.8 33.2
Density at 20℃ kg/m³ 1,087 1,093
Refracting index at 20℃ - 1.3814 1.3843
Alkalinity as NH3 % - 0.2
Biuret % - 0.3
Aldehyde mg/kg - 5
Insolubles mg/kg - 20
Phosphate (PO4) mg/kg - 0.5
Calcium mg/kg - 0.5
Iron mg/kg - 0.5
Copper mg/kg - 0.2
Zinc mg/kg - 0.2
Chromium mg/kg - 0.2
Nickel mg/kg - 0.2
Aluminium mg/kg - 0.5
Magnesium mg/kg - 0.5
Sodium mg/kg - 0.5
Potassium mg/kg - 0.5
1.5 Features of Weichai Power special oil
1.5.1 High-qualified lubricating oil
Adopt fine imported hydrocracking base oil and composite additives to ensure the
high quality of lubricating oil.
1.5.2 At normal use, the oil-change interval can be increased by 3,500~7,000km
(10,000km for CH-4); excellent oxidation resistance at high temperature and
excellent TBN retention will also prolong the engine life.
1.5.3 Professional protection to extend the engine life
Through a lot of performance and durability tests on Weichai diesel engines,
a professional oil formula suitable for high power and high load engines is
worked out. The special oil can provide the Weichai engine with special
protection and can significantly prolong their service life (by 30~40% in
contrast with others).
1.5.4 Better performance
It features of better wear resistance, TBN retention, anti-rust performance,
antioxidation, better fuel consumption control, shear stability and can reduce
sediments in the turbocharger.
1.5.5 Energy-saving
“Low viscosity + Multi-grade + Friction modifiers”, energy-saving formula,
high oil viscosity index, high oil-film strength and elasticity, thus the engine
3
can run stably with low resistance and low fuel consumption.
1.6 Difference between the Weichai Power special oil and common oils
Item Special oil Common oil
Most oils adopt domestic
Adopt the imported class IV
Base oil class I base oil, a few
hydrocracking basic oil.
adopt class II base oil
Mainly adopt the imported high-quality
Additive Domestic additive
composite additive.
With targeted professional formulation,
the special oil features good lubricating
and cleaning performance, and
effectively improves the fuel economy
Only meet the common
Performance (saving fuel by 3~8%) and provides
lubricating requirements
professional protection for the diesel
engine even in severe working
conditions such as heavy load and dusty
environment (heavy load or heavy dust)
At normal use, it can be extended by
Oil change
3,500~7,000km (for CH-4, 10000km Normal interval
interval
can be extended).
4
1.7 Some Common Products of Weichai Power Special Oils

Type Oil grade Viscosity grade Package capacity
15W/40
WP-E1(CD) 20W/50 4L, 18L, 200L
10W/30
15W/40
WP-E2(CF-4) 20W/50 4L, 18L, 200L
Diesel engine oil 10W/30
5W/30
15W/40
WP-E3(CH-4) 4L, 18L, 200L
20W/50
10W/30
WP-E4(CI-4) 15W/40 4L, 18L
Gear oil of heavy-duty 85W/90
GL-5 4L, 18L
vehicles 80W/90
1.8 Corresponding table between the Weichai Power special oil and engine
models
Special oil
Type Applicable engine models
grade
WP-E1
Medium-speed diesel engine sets
High- (CD)
speed
China I and China II diesel engine; construction
diesel WP-E2 machineries such as 50 and 30 loaders; WD618/WD12
engines
(CF-4) series, WD615/WD10 series; 226B and medium-speed
and high-
engine; 15T or more heavy-duty trucks
power
medium- Euro Ⅵ diesel engines; Landing engine series; extra-
speed WP-E3 large heavy-duty trucks and buses;
diesel WP4/WP6(165~270HP), WP10(240~375HP),
(CH-4)
engines WP12(336~460HP), WD10, WD12 and
WP5/WP7(160~300HP)
Compressed natural gas engine; Coach, generator sets and
Natural
CNG others equipped with compressed natural gas diesel
gas engine
engines.
5
1.9 How to select proper viscosity

Applicable ambient
SAE Viscosity grade
temperature (℃)
Lubricating 5W/30 -30~35

oil 10W/30 -25~35
15W/40 -20~40
20W/50 -15~50
85W/90 -15~49
Gear oil 80W/90 -25~49
85W/140 (viscosity higher than 85W/90) -15~49
1.10 Auxiliary materials
The applicable positions are shown in the following table:
Table 1-4 Auxiliary materials for WP7 Euro Ⅵ diesel engines
S/N Name Color Usage and Application
Molybdenum Acting as a lubricant before the lubricating oil
Dark
1 disulfide, oil pressure is built up. For example: coated on the
gray
solution intake valve stem etc.
Coated on the threads and outside surface of
2 Loctite 242 Blue bearings to prevent against any potential looseness
due to vibration, with medium strength.
Coated on the outside surface of threads, playing the
3 Loctite 262 Red role of locking, sealing and resistance to looseness
due to shock, with high strength.
4 Loctite 275 Green Coated on the pipeline and connection portion
Coated on the shiny metal surface to function as
Red
5 Loctite 510 sealing. For example: the joint faces of the cylinder
(Orange )
block and flywheel housing.
Suitable for sealing the space between core and hole
6 Loctite 277 Red and applied to the oil chamber and oil passage, such
as the cylindrical surface of bowl-plug.
Coated on the shining metal surface to function as
7 (Loctite 648) Green fixing, such as the inside hole of tensioning bearing
and outside surface of the shaft etc.
6
2 Regular inspection and maintenance of diesel engine

Table 2-1 Working conditions of matched vehicles
(WG I) (WG II) (WG III)
Working under severe
conditions (extremely cold
or hot; dusty; short distance
transport; working on
Annual mileage is less
construction site and city
than 60,000 km; short Annual mileage is longer
buses, municipal
or medium distance than 60,000 km; long
construction vehicles, snow
transport (goods distance transport
sweeper vehicles or fire
transport)
trucks) or annual mileage is
less than 20,000 km or
annual working hours is less
than 600h
Table 2-2 Intervals for 1st inspection, regular inspection and maintenance
Working
condition (WG I) (WG II) (WG III)
Item
Having traveled
1,000-1,500km or Having traveled Having traveled
1st inspection
having worked for 1,500-2,000 km 1,500-2,000 km
30-50h
Regular Every 5,000km or
Every 10,000 km Every 15,000 km
inspection every 150h
Grade 1 Every 10,000 km
maintenance or every 300h
maintenance or every 600h
maintenance or every 1,200h
maintenance or every 2,400h
7
Table 2-3 Oil changing interval according to vehicle maintenance specifications

(WG I) (WG II) (WG III)
Working
condition Annual mileage less Annual mileage Annual mileage
Item less than 60,000 longer than 60,000
than 20,000 km
km km
Having traveled for Having traveled Having traveled
1st inspection
1,000-2,000km 1,500-2,000 km 1,500-2,000 km
P Every 5000km Every 10,000 km Every 15,000 km
WD1 Every 10,000 km Every 20,000 km Every 30,000 km
8
Table 2-4 Oil changing intervals determined by oil working condition (changes with
the oil consumption)
Normal oil working condition (at normal oil Severe oil working condition
consumption) (at normal oil consumption)
Tropical or frigid zone
(temperature is always
A higher than +30℃ or
Ambient air temperature: -10℃ to +30℃ lower than -10℃)
Sulfur content of fuel: less than 0.5%
Sulfur content of fuel:
(by weight) B
0.5%-1.0%
Sulfur content of fuel:
C
1.0%-1.5%
Oil working condition Working condition
WG I Every 5,000 km
Normal condition WG II Every 10,000 km
WG III Every 15,000 km
WG I Every 5,000 km
Severe condition A WG II Every 5,000 km
WG I Every 5,000 km
Severe condition B WG II Every 5,000 km
WG I Every 5,000 km
Severe condition C WG II Every 5,000 km
WG I Every 5,000 km
Severe condition A+B WG II Every 5,000 km
WG I Every 2,500 km
Severe condition A+C WG II Every 2,500 km
9
Table 2-5 Maintenance specification of the engine
1st Regular Level 1 Level 2 Level 3 Level 4

Item
inspection inspection maintenance maintenance maintenance maintenance
Change oil (at
least once per ● ● ● ● ● ●
year)
Replace the
oil filter Each time when changing diesel engine oil
element
Inspect and
adjust the
valve ● ● ● ● ●
clearance
Replace filter
element of
the fine fuel ● ● ● ●
filter
Wash
coarse fuel
filter or ● ● ● ●
replace the
element
Inspect
coolant
amount and
add to ● ● ● ● ● ●
required
amount
Change the
Once a year
coolant
Tighten clips
on cooling ●
pipe
Tighten air
inlet pipe,
hose and ● ● ● ● ●
flange
connections
10
1st Regular Level 1 Level 2 Level 3 Level 4

Item
inspection inspection maintenance maintenance maintenance maintenance
Inspect
maintenance
indicating
light or ● ● ● ●
indicator of
air filter
Wash the dust
cup of air
filter
(excluding ● ● ● ● ●
the auto dust-
removal type)
Wash the air
filter main When the indicator is on
element
Replace the
air filter main Please refer to related regulations in the vehicle instruction manual
element
Replace the
air filter
After the main element has been washed for 5 times
safety
element
Inspect and
tighten the ● ● ● ● ● ●
belt
Inspect the
clearance of
turbocharger ●
bearings
Note: ● indicates that maintenance is required.

Engine shut down and stored for more than 6 months shall be maintained as
required. Suggestion or advice will be given based on the user’s requirements.
11
3 Common failures and Troubleshooting

3.1 The engine fails in starting
Causes Troubleshooting
Check and remove the blockage and check if the
1. Fuel pipe is blocked
fuel is clean
2. There is air in the fuel system Release the air and check air tightness of joints
3. High pressure fuel pipe is damaged
Repair it or replace it with a new one
and fuel leaks out
4. The ambient temperature is too low Use auxiliary start device
5. There is few fuel or no fuel left in
Check and refuel
the tank
3.2 The engine stops soon after starting
Disassemble the filter to clean and dry the inside;
1. Fuel filter is blocked
or replace it if necessary
Check the tightness of fuel pipes and the joints;
2. There is air in the fuel system check if the bleed screw is tightened; release the
air
3. Fuel is of poor quality, containing
Wash the filter and use high quality fuel
too much water
3.3 Engine Power is insufficient
1. Air inlet pipe is blocked (air filter Check and clean the air filter and air inlet pipe or
is blocked) replace the element
2. Exhaust back pressure is high Check if the exhaust pipe is blocked
3. The pressure of turbocharging Check and remove any leakage with the exhaust
system is insufficient pipe
check the fuel pipes and check if the filter is dirty;
4. Fuel pipe leaks or is blocked
Repair or remove any blockage; replace the filter
element
Wash the fuel tank, filter parts and fuel pipes;
5. Poor fuel quality
replace the fuel
6. High oil level Release the extra lubricating oil
12
3.4 High fuel consumption

1. Air inlet pipe is blocked Check the air filter and air inlet pipe to ensure
(air filter is blocked) smooth air-inlet
Check the exhaust pipe and braking valve to
2 Exhaust back pressure is high
ensure smooth exhausting
3. Poor fuel quality Replace the fuel as specified
4. Fuel pipe is blocked Check and remove the blockage
Check the leaking location and replace the
5. Fuel pipe leaks
pipe to ensure good sealing performance
3.5 Dark smoke in the exhaust
1. Air inlet is blocked or exhaust Check the inlet and exhaust pipe to ensure the
back pressure is high pipes are not blocked
2. Poor fuel quality Wash and replace
3. Wrong valve timing or injection
Adjust as required
timing
4. Injection pump injects too much
Check and adjust (by specialized operator)
fuel
5. The pressure of turbocharging Check if there is any leakage with the pipes
system is insufficient and joints
6. Malfunction of turbocharger Check and replace the turbocharger assembly
7. Intercooler is damaged or there
Replace or repair
is leakage
8. Wrong working point of smoke
Re-adjust (by specialized operator)
limiter
13
3.6 White or blue smoke emission

1. Poor quality fuel that contains too
Change the fuel
much water
Check working temperature of the
2. Coolant water has low temperature
thermostat or replace it when necessary
3. Wrong valve timing or injection
Check and adjust
timing
4. Injector nozzle poor atomization Check and repair
5. Low compression pressure,
Check the piston ring, cylinder liner and
incomplete combustion or cylinder
cylinder head gasket and repair them
scuffing
6. Poor running-in between piston rings
Running-in for more time
and the cylinder liner
7. Openings of piston rings are not
Adjust or re-assemble
staggered
8. Piston oil ring failure Replace
9. Excessive clearance between the
Repair or replace
piston and cylinder liner
10. Sealing ring of turbocharger is worn Repair or replace
11. Turbocharger thrust bearing is worn Check and replace
12. Turbocharger oil outlet pipe is
Wash or repair
blocked
14
3.7 Unstable speed

1. Poor quality fuel, containing too
Clean the fuel system and replace the fuel
much water or wax
2. Air comes into the fuel suction pipe
release the air
3. Governor weight and spring do not
Check and repair (by specialized operator)
work normally
4. Uneven fuel supply Check and adjust (by specialized operator)
5. Poor atomization of the injector
Check and repair
nozzle
Check the compressor flow passage and
6. The turbocharger surges remove the blockage, remove the carbon
deposit in the exhaust path
7. Turbocharger bearing is broken Replace
3.8 Low oil pressure

1. Low oil level in the oil sump or lack Check the oil level and leakage; repair and add
of oil oil
2. Failure of pressure regulator in the
Check, clean and repair the valve
main oil passage
3. Oil strainer, oil pipe, joint gaskets are Check the oil strainer and joints, repair the
blocked or broken casting shrinkage porosity if any
4. Unqualified oil grade Replace with qualified grade
5. Oil inlet pipe of the engine oil pump
Examine the oil pipe, joints; repair or replace
leaks
6. The temperature of water in cooling
Check the working conditions of cooling
system is too high, and temperature of
system, and correct
lubricating oil is too high
7. The resistance of oil filter is too big Replace with a new element
8. Oil cooler is blocked Check and remove the blockage
9. The main oil passage is blocked Check and remove the blockage
10. Excessive bearing clearance or the
Check and repair
bearing is damaged
11. Excessive wear of parts, overhaul is Check the working hours of the engine and
required carry out an overhaul
15
3.9 High temperature of cooling water

1. Low water level in water tank Check if there is any leakage and add water
2. The water tank is blocked Check the water tank to clean or repair
3. The water pump belt is loose Tighten the belt as specified
4. Water pump gasket is damaged and
Check and repair or replace
the pump impeller is worn
5. The thermostat failure Replace
6. The water pipe is broken and air Check the water pipe, joints, gaskets, etc;
comes into the pipe replace the damaged ones
7. Low oil level in the oil sump or lack Check the oil level and leakage; repair and add
of oil oil
3.10 Early wearing of parts

1. Unqualified or damaged air filter
Check, replace with a qualified element
element
Check the air inlet pipe, gasket,
2. Short-circuit of the air inlet system
connecting sleeve, repair or replace
Check the oil level and leakage; repair and
3. Low oil level in the sump or lack of oil
add oil
4. Oil passage is blocked Remove blockage in the oil passage
5. Unqualified oil grade Change the oil as specified
6. Piston ring is broken or worn Replace the damaged parts
7. Cylinder liner or piston is worn or Disassemble the piston and cylinder liner,
scuffing repair or replace;
8. Oil filter element is not replaced in time Replace as required
9. Excessive wear of parts, requiring Check the mileage and determine to carry out
overhaul overhaul
10. The crankshaft is not coaxial with the Check the mounting bracket, and repair if
main shaft of driven parts necessary
11. Unqualified oil Adopt oil of right grade
16
3.11 Loud noise

1. Poor fuel quality Replace the fuel
Check the thermostat or replace it if
2. Cooling water has low temperature
necessary
3. Wrong valve timing or injection timing Adjust
4. Injector nozzle has poor atomization Check and repair
Check and adjust (by specialized
5. Injection pump injects too much oil
operator)
Check if the absorber is damaged; check
6. Shock absorber is damaged the connecting bolts and replace them if
necessary
7. The valve has leakage or improperly
Disassemble the valve and adjust
adjusted
8. Too large gap between gears or some tooth
Check and replace the damaged parts
is broken
9. Cylinder liner or piston is worn or scuffing Check, repair or replace
10. Push rod is bent or broken Replace
11. Piston ring is broken or worn Replace
12. Bearing is worn seriously Replace
13. Excessive crankshaft thrust bearing
Replace
clearance
14. Main bushing is not concentric Replace
15. The crankshaft is not coaxial with the Check the bolts on the mounting bracket
main shaft of driven parts and repair
16. Parts are worn seriously, requiring an
Overhaul
overhaul
Remove dirt and blockage in the
17. Turbocharger surges compressor flow passage and
accumulated carbon in the exhaust path
18. Sealing ring of the turbocharger is burnt Replace
19. Turbocharger bearing is damaged; moving
Replace
part rubs against fixed part
20. Foreign matters come into the turbine or
Replace
the compressor impeller of turbocharger
17
3.12 The starter motor does not work

1. The battery is not fully charged Examine, charge or replace the battery
2. Wires are nor well connected Well connect the wires
3. Fuse is burnt Replace the fuse
4. Electric brush has poor contact Clean the bush surface or replace the bush
5. The motor itself is short circuited Repair the motor or replace the assembly
3.13 The generator does not work at all

1. Wires are open or short circuit or the Check the wiring of the generator and ampere
connectors are loose meter and repair
2. Rotator and stator coils are open or
Repair or replace the assembly
short circuit or grounded
3. Rectifier tube is damaged Replace the assembly
4. The paper insulation of the terminal
post is damaged, the wire is Repair
disconnected
5. The voltage of adjustor is too low Repair
6. Contacts of adjustor are burnt Repair or replace the assembly
3.14 Undercharged generator

1. Wires are open or short circuit or the connectors are
Repair
loose
2. Rotator and stator coils are open or short circuit or
Repair or replace the assembly
grounded
Repair and adjust the belt
3. Generator belt is loose tension
4. Damaged generator rectifier tube or poor
Repair
contact of brush
5. The voltage of adjuster is too low Adjust
6. Disconnected field coil or resistor wire of the
Repair or replace
adjuster
Add electrolyte or replace the
7. Insufficient electrolyte or the battery is old battery
18
3.15 Unstable generator charging current

1. The stator or rotor coil is about to open or
Repair or replace.
short circuit
2. Poor contact of brush Repair
3. The terminal is loosened with poor contact Repair
4. The voltage adjuster is damaged Repair
5. The voltage is improperly adjusted Check and adjust.
3.16 Overcharged generator
1. Internal short circuit of battery Repair or replace
2. High adjuster voltage Repair and adjust
3. Poor grounding of adjuster Repair
4. Contact failure or contamination of
adjuster; the voltage coil or resistor wire is Repair or replace
open
3.17 Abnormal generator sound
1. Improper installation of generator Repair
2. Damaged bearing Replace the bearing
3. Moving part interferes with the fixed part Repair or replace
4. Rectifier short circuit Replace
5. Stator coil short circuit Repair or replace
3.18 Abnormal pressure of the urea solution pump
1. The filter element of urea solution pump is
Wash or replace the filter element
blocked
2. Poor urea solution quality, containing too Replace the urea solution and wash
much impurity the urea solution tank
3. Urea solution nozzle is blocked Replace
19
3.19 Abnormal indication of the urea solution level

1. Liquid lever sensor of urea solution-tank is
Check and replace
failure
3.20 Urea-crystal appear at the nozzle position on the exhaust pipe
1. Wrong urea solution nozzle mounting size Check and adjust
2. The nozzle has leaked Check and replace
20
WP7 Euro Ⅵ Vehicle Diesel Engine User Service Guide
II. User Service Guide (warranty card)

Weichai Power Product Warranty Card (Kept by user)
Item Content Item Content
Model User’s name
Order No. Zip code
Number: Address
Purchasing date Office phone
Distributor Home phone

Respected users:
Thank you for using Weichai products, and we appreciate your trust! In order to
correctly use and maintain the diesel engine, please carefully read this manual and
closely follow the specifications. In case of any failure, please timely contact with the
Weichai Maintenance Center or Customer Service Center and we will delivery
effective service on time.
“Service Registration Form” should be filled by the Maintenance Center during
service and then kept by the user.
Weichai Power Co., Ltd.
Address: No. 26 Minsheng East Street, Weifang, Shandong, China
Zip code: 261001
Website: http://cn.weichaigroup.com
Engine sale phone: 0536-8232488; 0536-8233371
Spare part sale phone: 0536-2297313; 0536-2297319
Service Hotline:
400 Free Service Hotline: 400-6183066
800 Free Service Hotline: 800-8603066 }
24h service phone
Customer Service Center: 0536-8235369 (Fax)

Customer service center complaint phone: 0536-2297335
21
Service Registration Form (filled by the service staff)

Item Content Item Content
Model User’s name
Order No. Zip code
Number: Address
Purchasing date Office phone
Dealer Home phone
Service Center Maintenance Replaced Signature of Signature

Date Quantity
Name items parts service staff of user
22
Warranty Explanations
1. Service commitment
In the service area of our service centers, after receiving the calls for help from the
users and confirmed that the service is needed, service personnel of Weichai will
arrive at the service site within 3h (cities), 24h (general areas) and 48h (remote areas)
(force majeure excluded).
2. Special notes
● The diesel engine operators must read the operation and maintenance manual
carefully to get familiar with the structure, strictly observe the technical operation
and maintenance regulations, and pay attention to the warning notes and signs.
● Before delivery, the diesel engine has been tested strictly according to the test
specifications, the test ECU data shall not be changed after delivery; otherwise,
Weichai will not undertake the liability for warranty.
● There are strict torque requirements and use times for all bolts of the diesel engine,
so do not loosen the main bearing bolts or the connecting rod bolts at will. Refer
to the operation and maintenance manual for the specific requirements.
● Carry out 50h test run before normal using of the new engine.
● After cold start of the diesel engine, increase the speed slowly; do not speed up
suddenly or idling for a long time.
● It is prohibited to run the diesel engine if no air filter is equipped, otherwise, the
unfiltered air may enter the cylinder. When the diesel engine works under severe
environment, increase the cleaning or replacement frequency of the filter element
to avoid early wear of the diesel engine.
● The fuel and oil should be filtered before filling. And the fuel and oil grade should
be selected according to the manual. Weichai Power special oil must be used.
3. “Three guarantees” principle and provisions

(1) “Three guarantees” principle
● For Weichai product or engine equipped with Weichai product purchased by the
users, under normal operation and maintenance conditions, Weichai will provide
“three-guarantee” service during the “three-guarantee” period for damages
caused by product manufacture and assembling.
● For damages of diesel engine and parts, repair will mainly be provided or
corresponding parts be replaced if repair is impossible; the diesel engine can be
replaced only if the replacement conditions are met and should be submitted for
23
approval of the leader.

(2) Three guarantee period
● For the Weichai’s end products, the three-guarantee service and warranty start
from the purchasing date and take the Weichai invoice and warranty card or
dealer’s invoice as the basis (the warranty period of marine engine starts from the
commissioning date).
● For the engines matching with vehicles, the three-guarantees service and warranty
should be implemented in accordance with the agreement. If the vehicle
manufacturer has specific provisions on the “Three Guarantees” warranty of
diesel engine, the provisions of vehicle manufacturer shall be followed firstly
based on the warranty card attached. Otherwise, the provisions of Weichai shall
be followed. The “Three guarantees” service and warranty period shall start from
the actual purchasing date of the vehicle and shall be based on the sales invoice
and warranty card.
● For damages of Weichai spare parts due to original quality problem, the “three-
guarantees” period of assemblies is 3 months, that of basic parts is 1 year, and no
warranty is provided for the wear parts, rubber parts, piston rings, oil seals,
bearings, bolts and fuel injector matching parts once they are mounted on the
engine. For quality problems of basic parts during within “three-guarantee”
period, after site confirming and getting effective photos by service personnel of
stationed abroad service center and effective photos, the working hours fee for
“three guarantees” service will be charged for “three-guarantee” service. The
“three -guarantees” period of spare parts is based on the date of the purchasing
invoice issued by the central warehouse storage or authorized service center. For
quality problems due to assembling, Weichai will not provide the “three
guarantees” service.
4. No “three guarantees” for the following situations
● Engine failures caused by improper operation, maintenance and matching;
Damages or failures caused by loading/unloading during user’ transportation;
operation conditions exceeding the range specified in the operating manual of the
product, mismatching, overload or overspeed operation, running-in and
maintenance not carried out according to the operating manual, or use of inferior
oil/fuel, antifreeze and filters (air, fuel and oil).
● Failures caused by self modifying, adjusting or dismantling any parts which are
not allowed in Manual.
● Oil, antifreeze, filter element, hose, belt and fuel injector matching parts which
are replaced in normal use, consumption or maintenance.
● No warranty card, invoice or cannot demonstrate that the products are still within
24
“Three guarantees” period. The product model and type on the “Three guarantees”
certificate or invoice are not consistent to that claimed to be guaranteed by “Three
guarantees”, or the “Three guarantees” certificate or invoice is modified.
● The original state of damage is not kept causing that the reason of fault cannot be
identified.
● Failures caused by improper operation.
● Damage caused by force majeure, such as war or natural disaster etc.
● Engine is damaged by the traffic accidents.
25
“Three guarantees” period for diesel engine of Weichai Power

S/N Product model Three guarantees period Remarks
I. Diesel engine
1 Diesel engine for road vehicle 1 year or 60,000km
2 Diesel engine for engineering vehicle 6 months or 30,000km
3 Diesel engine for bus 1 year or 100,000 km
4 Natural gas engine for bus 1 year or 100,000 km
II. Diesel engine parts
2 years or 200,000km (due to
1 Basic parts Cylinder block, crankshaft, engine base, connecting rod original manufacture defects, such
as sand inclusions )
Cylinder head, flywheel, flywheel housing, connecting rod

bolt, piston, piston ring, piston pin, connecting rod bearing Subject to
shell, main bearing, cam bearing, camshaft, cylinder liner, the actual
valve, valve spring, valve seat, valve guide, valve cover, tappet, purchasing
tappet, push rod, rocker arm and shaft, gears and gear shafts, date and
tensioner, gear ring, oil pump, intake/exhaust manifold, oil based on the
sump, belt pulley, injection pump, fuel injector body, air invoice,
Same with the three guarantees
2 Key parts compressor, cover plates and shim plates, water pump, oil warranty
period of the diesel engine.
radiator, silicone oil clutch, relief valve, shock absorber, card or
crankshaft balancing mechanism, metal oil/water pipes and timer.
pipe joints, steering pump, thermostat, oil-gas separator,
cylinder gasket, ECU, common rail pipe, air filter body, diesel
filter body, oil filter body, muffler, distributor, starting valve,
intercooler, heat exchanger, air bottle, thrust plate, strainer,
dipstick component, coolant nozzle and etc. Three
guarantees
period or
Road vehicle: 6 months or mileage
Front oil seal and other oil seals; turbocharger, intake manifold 30,000km. (hour),
gasket, exhaust manifold gasket, turbocharger gasket, valve whichever
Common Engineering vehicle: 3 months or
3 cover gasket, rubber hose, return pipe of injector, fuel delivery comes first.
parts 15,000km.
pump, oil dipstick, fan, waterproof rubber ring, oil-proof
rubber ring, bowl-shape plug. Passenger car: 6 months or
50,000km.
Road vehicle: 6 months or
30,000km.
Starter, generator, instrument, sensors, electronic speed
Engineering vehicle: 3 months or
4 Electric parts controller, accelerator pedal, harness, solenoid valve, flame
15,000km.
preheater.
Passenger car: 6 months or
50,000km.
5,000km; or within the mandatory
Belt, fan shroud, nozzle, plunger and barrel assembly, other
5 Wear parts maintenance period; for passenger
gaskets; braided hoses, clamp, timer.
car: 1 month or 10,000km
Remarks: 1. If the odometer of the road vehicle is damaged, the three-guarantee period of the diesel engine will be calculated as per
325km per day;
2. If the odometer of the engineering vehicle is damaged, the three-guarantee period of the diesel engine will be calculated
as per 300km per day;
3. If the odometer of the passenger car is damaged, the three-guarantee period of touring coach diesel engine will be
calculated as per 400km per day and that of public bus will be calculated as per 200km per day;
4. The road vehicles include transportation trucks, truck-mounted crane, cement mixer; and the engineering vehicles include
dump trucks, etc.
5. The provisions of vehicle manufacturer shall be observed if explicitly stipulated.
26
Weichai international marketing service network

Weichai International Marketing Service Network
Office Service in
Area Office (city) No. Mobile China mobile E-mail Address
(country) charge
0079267519073
1 An Pengfei 13869608008
0079647932613
2 Zhang Mingli 0079651290588 13806468357
3 Yang Chunhui 0079251070970 15866537430
4 Sun Shouli 0079651298369 15953614932 [email protected]
Russia Moscow
CIS 5 Ge Tiannan 0079258219103 18765633071 [email protected]
6 Ma Shizhu 18660616360
Meng
7 0079036815065 18365681128
Xiangchen
8 Cao Meng 13153660087
9 Sun 0097699602398 18953658057
Mongolia Ulaanbaatar [email protected]
10 Shi Xiaochuan 0097694800661 15965090504
11 Zhang Meng 15153682611
12 Li Jie 0077014489958 13666360667
Kazakhstan Almaty 13 Shi Guopeng 0077013522786 15965090719 [email protected]
居玛艾力·吐尔
14 13780819457
逊
Zhao
Tajikistan Dushanbe 15 00992929630037 15269665590 [email protected]
Xiaoguang
Uzbekistan Tashkent 16 Liu Mingyu [email protected]
Azerbaijan Baku 17 Shan Hongwu 0077011725466 13964631238 [email protected]
Cheng
Singapore Singapore 18 0065 83547257 13325250488 [email protected]
Shouliang
19 Li Hao 006281213421256 13696364283
20 Wang Zhi
Indonesia Jakarta [email protected]
21 Li Guotao
22 Yan Dezhong 006281212562558 18953611016
23 Zhang 0063 9053389899 13695368355 [email protected]
Philippines Manila
24 Liu Ningyu 006309327870038（Cebu） 18953658101
25 Xu Hongluan 00601123525072 13864627796
APAC Malaysia Kuala Lumpur [email protected]
26 Li Xinlong 00601123525081 18953658012
Laos Vientiane 27 Zhou Jingwei 13964700450 [email protected]
28 Hu Xudong 0066-867001639 13884712915
Thailand Bangkok 29 Bi Yonggang 0066-867001658 13869621831 [email protected]
30 Yang Yongbo 0066-924461323 15265816007
Myanmar Yangon 31 Sun Shaojie 0095949325397 15094931767 [email protected]
32 Ning Aizhong 0084904315108 13562632375
Vietnam Hanoi 33 Liu Jian 0084904351873 18953658030 [email protected]
34 Zhang 0084916681084 15964585240
35 Pan Shankao 00917387006182 15053609833
India New Delhi 36 Wang Xiujun 00917387523070 18953658050
South [email protected]
37 Lin Shilong 00917757004650 18615080279
Asia
Bangladesh Dhaka 38 Zhang Yong 0091711542654 18953658139
Pakistan Islamabad 39 Liu Haitao 13562645194 [email protected]
27
Weichai International Marketing Service Network

Office Service in
Area Office (city) No. Mobile China mobile E-mail Address
(country) charge
40 Luan 00989122146779 18663666289
Iran Tehran 41 Song Weihua 00989124048462 13953675677 [email protected]
42 Wang Dong 15265617851
Middle United Arab 43 Chen Yun 00971509420629 15965081508
Dubai [email protected]
East Emirates 44 Wang 00971502616210 15165366953
45 Sui Zhen 00966562108200 15866165882
[email protected]
Saudi Arabia Riyadh 46 Shi Hongbo 00966563345830 13863655364
[email protected]
47 Yu Chunbo 966532738055 15866504651
48 Huo Chunlei 00213551883843 13863674728
Europe 49 Meng 00213560304723 13280138531
Algeria Algiers [email protected]
and 50 Gu Yingchun 0021-3555477841 15165360725
North 51 Ren Shunli 18953621166
Africa Libya 52 Liu Hui 18615918089
Turkey Istanbul 53 Zhang Lei 13706468642
54 Cai Lei 00254-705978578 13583683720
55 Zhao Yukuan 00254717540993 13563666046
Kenya Mombasa
56 Guo Yuhua 00254-0718922892 15169643957
East [email protected]
57 Li Zhonghua 15153607233
Africa
Wang 00254712299408
Tanzania 58 13475660013
Dongmin 00255-758355846
Addis Ababa 59 Hu Xiaoqun 00251924909463 13475680218
Ethiopia [email protected]
60 Zhao 18764697679
00249922868539 00249
61 Ma Xiaoxiao 15095105086
the Sudan Khartoum 908750077 [email protected]
62 Wang Yushuai 00249968126616 15165645631
63 Guan Feng 0027837673902 13706468624
South Africa Johannesburg [email protected]
64 Xun 0027-834252377 15153633170
South
65 Fu Yongsheng 00244924771275 13696363763
Africa
Angola Luanda 66 Du Wenchao 00244934192717 15165600735 [email protected]
67 Yan 18606365360
68 Song Zhiping 13678660757
West Nigeria Lagos 69 Hou Jie 18953610203 [email protected]
Africa 70 Yu Qianjun 00234-8109983128 15165363587
Zhang
71 00233544430761 15006652638
Haisheng
Ghana [email protected]
72 Wang Jiaquan 002348155777771 18663671909
73 Du 00989124048461 15866188500
74 Chen 005511976427085 13515405118
Brazil Sao Paulo 75 Han Pengji 18953658011 [email protected]
76 Zhang Lei 005511976427085 13475685957
0056965146276（Chile）
South Chile Santiago 77 Lin Chuanmei 15964585510 [email protected]
00593992848964（Ecuador）
America
78 Zhang 0051984131788 15863619226
Peru Lima 79 Li Peng 0051943058834 15628706366 [email protected]
80 Qin Shude 13853660409
Ecuador 81 Wang 18765360251
28
The European Union representative office
office address: Societe international des Moteurs Baudouin

CS50001 FR-13711 Cassis France
Linkman: Zhang Guoping (Paul. Zhang)
Mobile(in China): 008618953658085
Email: [email protected]
29
Diesel engine mandatory maintenance card

License plate number Manufacturer
First copy
User’s name Diesel engine No.
Detailed address Date of mandatory maintenance
Mileage of mandatory maintenance
Purchaser Purchasing date
Identifier: Signature of user: Weichai Power special oil
Stub
Official seal of service station: Valid documentation: label:
Phone:
Friendly reminder: The mandatory maintenance card should be filled out triplicate and must be signed by the user. Omission of items
will cause the card invalid.
Weichai Power supervisory phone: 400-6183066 800-8603066
After mandatory maintenance, this card and the Customer Satisfaction Questionnaire will be collected by the service station and submitted
to the reginal office.

First copy
Stub
Phone:
to the regional office.

First copy

Detailed address Date of compulsory maintenance
Mileage of compulsory maintenance
Stub

Phone:
30

2nd copy, kept by Weichai for filing

Phone:


Phone:


Phone:
31

3rd copy, kept by the service station

Phone:


Phone:


Phone:
32
Customer Satisfaction Questionnaire

Not
Item Evaluation factor Excellent Good Acceptable Bad
acceptable
Diesel Appearance
engine Performance
product
quality Reliability
Engine completeness
Diesel Attached spare parts
engine and tools
delivery Attached engine
quality documents
Delivery time
Diesel Service promptness
engine Service quality
service
quality Service attitude
Customer
cancellation
Return of products
Others Additional
transportation
Other opinions of
users
Customer’s seal
MM, DD, YY
Customer Service Center, Weichai Power Co., Ltd.
Address: No. 26 Minsheng East Street, Kuiwen District, Weifang City, Shandong Province
Zip code: 261001
Phone: 400-6183066 (for mobile phone or landline) 800-8603066 (for landline)
Fax: 0536-8235369
Note: please mark the “√” in the corresponding “column”.
33

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Operation & Maintenance Manual and User Service Guide

WP7 Euro Ⅵ Vehicle Diesel Engine

WP7 Euro Ⅵ diesel engine outside view ........................................................................... 6

WP7 Euro Ⅵ diesel engine outside view

The meaning of diesel engine model

Diesel Base Parameter

the Parameter of WP7 Euro Ⅵ diesel engine

Tools and equipments:

torque wrench sleeve wrench adjusted wrench

I. Operation & Maintenance Manual for WP7 Euro Ⅵ

1. Do not check the oil level during operation.

Table 1-1 Selection of oil grade

Items Unit Min limit Max limit

1.7 Some Common Products of Weichai Power Special Oils

1.9 How to select proper viscosity

Lubricating 5W/30 -30~35

2 Regular inspection and maintenance of diesel engine

Table 2-3 Oil changing interval according to vehicle maintenance specifications

Table 2-5 Maintenance specification of the engine

1st Regular Level 1 Level 2 Level 3 Level 4

1st Regular Level 1 Level 2 Level 3 Level 4

Note: ● indicates that maintenance is required.

3 Common failures and Troubleshooting

3.4 High fuel consumption

3.6 White or blue smoke emission

3.7 Unstable speed

3.8 Low oil pressure

3.9 High temperature of cooling water

3.10 Early wearing of parts

3.11 Loud noise

3.12 The starter motor does not work

3.13 The generator does not work at all

3.14 Undercharged generator

3.15 Unstable generator charging current

3.19 Abnormal indication of the urea solution level

II. User Service Guide (warranty card)

Model User’s name

Order No. Zip code

Purchasing date Office phone

Distributor Home phone

Customer Service Center: 0536-8235369 (Fax)

Service Registration Form (filled by the service staff)

Model User’s name

Order No. Zip code

Purchasing date Office phone

Dealer Home phone

Service Center Maintenance Replaced Signature of Signature

3. “Three guarantees” principle and provisions

approval of the leader.

“Three guarantees” period for diesel engine of Weichai Power

Cylinder head, flywheel, flywheel housing, connecting rod

Weichai international marketing service network

Weichai International Marketing Service Network

The European Union representative office

office address: Societe international des Moteurs Baudouin

Diesel engine mandatory maintenance card

Diesel engine mandatory maintenance card

Diesel engine mandatory maintenance card

User’s name Diesel engine No.